International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Preparation of W.P.S for Stainless Steel (Ni, Cr,

Mo, Nu) Welding
W.r.t Mechanical & Thermal Properties
D.Kumar

M.Valliappan

B.E (Mech)
Shivani College of Engg. & Tech., Trichy
Tamilnadu
kumarkumar455@gmail.com

M.Tech (Manu.Tech)
PRIST UNIVERSITY, Tanjore
Tamilnadu
smartvalli@gmail.com
Abstract Today Most commonly used materials in boiler, and
o

also in boilers accessories are S.S which will operate under 700 C
with greater performance (creep strength, corrosion resistance)
and reliability, especially for temperatures of 700-750oC.The
modern technology in welding of materials goes towards anticorrosion, wear resistance to increase the service of a product. In
S.S alloys, Ni content is very good against corrosion resistance;
hence we have selected Stainless steel 321, 316 and 347 materials,
Which consist of (Ni,Cr,Mo,Nb) widely used for Power piping in
800MW, 1000MW Boiler. In order to maintain the properties of
material properties before and after welding, we have Prepared
Welding Procedure Specification (WPS) based on the thermal
and mechanical properties of materials.

I. INTRODUCTION
This paper deals with the preparation of Welding procedure
specification for SS welding by optimizing the existing WPS
method with respect to mechanical and thermal properties. It
also aims to reduce the creep, fatigue, Residual stress and
thermal stresses in the Boiler materials by the application of
stainless steel material and welding it.
Stainless steels are weldable materials and a welded joint can
provide optimum corrosion resistance, strength and fabrication
economy. However it may undergo certain changes during
welding it is necessary to take care of welding to minimize the
defects and to maintain the same strength and resistance in the
weld zone that is an inherent part of base metal. Seamless
Tubes of 316 and 347 and 321 plate materials having
improved austenite stability. The stability of the austenite in
CrNi and CrNiMo steels is achieved by increasing the nickel
content over that of standard 18/8 CrNi and 18/8/2 CrNiMo
steels, and more especially by additions of nitrogen, which is
particularly effective in promoting the austenite stability.
The project starts with micro testing and chemical analysis of
materials and preparation of WPS based on thermal and
mechanical properties. Finally calculating the strength of
material and to replace the current boiler materials in to
improved SS materials. In welding by controlling the
parameters of thermal property mechanical deviations are
reduced and so weld with less defect could be obtained and
also the service life of material will be increased.

II. SS MATERIALS
In this paper we are going to weld the 321(Plate) of 5.6mm
thick, by TIG and ARC similarly 316(Seamless Tube) of
60.3mm, 6mm thick, 347 (Seamless Tube) of 60.3mm,
and 5mm thick by TIG and ARC. Welding is carried out by
preparation of WPS under the Properties of the material. The
main Purpose of the choosing the TIG and ARC welding is
based on the material thickness apart from this TIG gives
Higher Accuracy and ARC gives in vice versa. The main
purpose of choosing Nb,Mo,Ti in Ni alloy combination is
because SS 347 contains Nb which has high Creep Strength,
where SS 316 consists of Mo, it has Fatigue strength, and 321
contains Ti which has high Ductility.
III. CHEMICAL & MICRO RESULT
SS321:
Grain
: FSS and ASS grains
ASME Grain Size
: No: 7
SS316:
Grain
: FSS and ASS grains
ASME Grain Size
: No: 7
SS347:
Grain
: Ferrite & Austenite grains
ASME Grain Size
: No: 8
IV.WPS (Existing Method)
The welding procedure form contains all of the essential
information required to make the weld and verify the test
result. This information may include the type of base and filler
metals, welding process used, preheat, inter pass or post weld
heat treatment shielding gases and so on.
(Ref-Book-PQR, Chap 24. Page No 380)
Base metal
Filler metal
Position
Preheat
Electrical characteristics
Technique
Parameters
Joints

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

V.WPS (REVISED)

Hence based on the selection of methods from the above

mentioned conditions welding could be carried out. In this, for
each case of the above mentioned parameters certain methods
are chosen according to AWS and WPS, so that welding could
be achieved in a greater extent of accuracy.

IV.A.TIG
Polarity
Composition
Color Code
Inert Gas

VIII.PREHEATING & POST HEATING

Preheating is done under the Environmental condition by
adjusting the current and voltage before welding, generally
material with less thickness are not to be considered for pre
heating and post heating will be carried out in case of any
defects in the weld. After welding heat treatment is required,
to maintain the material strength and other properties.

V.B.ARC
V.B.1. BASE METAL
Position
Edge preparation
Root Gap
Cleaning
V.B.2. ELECTRODE
Type
Diameter
Arc length
Coating
V.B.3. PROCESS
Polarity
Bead
Technique
Run
Speed
Pre heating
Post heating
Heat treatment
By optimizing the above mentioned parameters with
existing W.P.S the strength of a material could be increased.
VI.NEED OF WPS
Welding could be done without preparation of WPS, but
which may results in improper weld or with defects like weld
decay, knife line attack and stress corrosion cracking. To
avoid such cases WPS is followed in all industries .Sometimes
Improper welding will increase the strength due to this the life
time of materials may be changed.
To overcome those weld defects WPS is optimized, use
extra low carbon electrode, avoiding hylogen family
VII.WELDING PROCESS
Welding is carried out by following parameters based on
Polarity- Straight and Reverse
Position Down hand, Vertical, Horizontal and 1G, 2G, 5G
Process TIG and SMAW
Bead Stinger and weaving
Technique - Forehand and Backhand
Speed low and high
Edge preparation based on angle (more than 75)
Root gap - based on thickness
Diameter of electrode based on thermal conductivity
Arc length shorter, longer and correct
Run Longer, shorter, skipping, alternate skipping
Preheating based on thickness of material

Preheating Conditions:
For S.S chromium and nickel equivalent is very
important and for other alloys carbon equivalent.
For Stainless Steel:
Chromium Equivalent = %Cr+%Mo+%1.5%Si+0.5%Nb
Nickel Equivalent = %Ni+30%C+0.5%Mn
Carbon Equivalent =%C + %Mn/4 = % Si/4 for carbon steel
Carbon Equivalent= %C+ %Mn/6 + %Cr/5 + %Ni/15 +
%Mo/4 +%V/5 for AS and SS
CE <40
No preheating
CE= 40to70
Preheating 100-300c
CE>70
Welding is difficult
Preheating Temperature=1000[C -0.11] + (1.8*thickness) F
Preheating Temperature:
P1
t<19
nil
P1
t>19
100-150c
P4
all
200-300c
P5
all
200-300c
IX. ELECTRODE (Ref-A.W.S)
E 308
Corrosion resistant
E 316, 317, 330 High temperature strength
E 410, 420
Abrasion resistant
X. WELDING METALLURGY
Ref -ASME Section IX
Voltage: V =17.34 + 0.023I - 6.3*10-6I2
Speed: S=1.6*106I-6.38
Deposition
Y=1.5 + 0.17I + 0.000028I2
Q=VI / S (without heat transfer)
Q=VI / S (with heat transfer)
Power Density Range:
SMAW
5*106 TO 5*108 Watts /m2
GMAW
SAME TO SMAW
PAW
5*106 TO 5*1010
EBW, LBW
1010 TO 1012
Stress Analysis:
Stress due to Sustained load = 0.72 Sy
Stress due to Occasional load=0.80 Sy
Sy = Min Yield Strength of material

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Sy = 0.6 to 0.7 of Tensile Strength

Stress due to Expansion load = E T Sh
E= youngs modulus
=Coefficient of linear expansion

analyzed. Thus optimization of welding process is also made

by checking the strength of each material in different welds.
Similarly reading from TIG and SMAW also compared for the
three materials. Strength is calculated manually and compared
with the ASME, WPS and AWS.
The main factor for choosing TIG and SMAW is, in boiler at
higher altitude PAW, EBW, LBW and other type of welding
could not be carried out and also it seems to be very expensive
hence to overcome such cases TIG and SMAW is selected.

T=Change in temperature
=Poissions ratio
Sh=Hoop stress
Resultant Bending Stress = (Ii Mi2+I0M02)1/2 / Z
Ii=SIF at inplane
Io=SIF at outplane
Mi=BM at inplane
M0=BM at out Plane
Resultant Torsional Stress =
Z= Section Modulus
Mt=Torsional Bending Moment

REFERENCES

Material: (AWS & ASME Sections)

Tensile Strength
=15.4(19.1+1.8%Mn+5.4%Si+0.025%pearlite+0.5d-1/2)
Hardness Vickers test
= 90 + 1050%C + 45%Si + 97%Mn + 30%Cr + 31%Ni
XI. APPLICATIONS
Non-ferrous metals with high strength and toughness
Magnetic properties, nuclear power systems
Corrosion resistance, wear resistance
Aerospace aircraft gas turbines
Steam turbine power plants, medical applications
Chemical and petrochemical industries
Strength at elevated temperature.
Nickel- chromium alloys or alloys that contain more than about
15% cr are used to provide both oxidation and carburization
resistance at temperatures exceeding 760C.

References:
1. Parmar.R.S. Welding Engineering and Technology,
Khanna publishers, Delhi. (1997is carried out by
following
2. Avanar Material science Engineering
3. Dr.Srinivasan Engineeering Materials
4. Peter Mayr , Stefan Mitsche, Horst Cerjak , Samuel
M.allen The impact of weld metal creep strength on
the overall creep strength of 9% Cr steel weldments ,
Journal of engineering materials and technology , vol.
133(2011) .
5. Nattaphon
TAMMASOPHAN
,
weerasak
HOMHRAJAI , Gobboon LOTHONGKUM Effect
of post weld heat treatment on microstructure and
hardness of TIG weldment between P22 and P91
steels With inconel 625 filler metal, Journal of
metals, materials and minerals , vol.21(2011) .
6. Samsiah Sulaiman Structure of properties of the heat
affected zone of P91 creep resistant steel, Research
work.
7. Greg j. Nakoneczny ,carl c schultz Life assessment of
high temperature headers, American power
conference(1995).

XII. CONCLUSION
The various SS material was welded by TIG and ARC and
finally the following test are carried out,
Hardness test
Impact test
Bend test
Tensile test, is carried out after welding to measure the strength
of 321, 316, 347 which are compared with the reading from
AWS, ASME and finally the suitable boiler material is

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